Method of manufacturing formed or molded articles



Nov. 8, 1938. J. A. BA'BOR 2,135,554

METHOD OF MANUFACTURING FORMED OR MOLDED ARTICLES 7 Filed March 9, 1937 Q INVENTOR j JqselyBabon mi ilg w I I U 6 6 Patented Nov. 8,1938 2 2,135,554

x1? i UNITED STATES PATENT OFFICE METHOD OF MANUFACTURING FORMED OR MOLDED ARTICLES Joseph A. 'Babor, New York, N. Y.

Application March 9, 1937, Serial No. 129,782

4 Claims. ,(Ol. 18-48) This invention relates to the manufacture of sary for the binding material to assume the formed or molded articles (pipe coverings, blocks, active properties of a binder. This may be a boards and the like) from exfoliated zonolite matter of moments or of a few minutes, dependand the like and provides an improved method ing upon the nature of the binding material and for such manufacture with improved propertim the liquid or solvent used. Thereafter the mass in the product. may be dried to remove (and to recover if this The invention provides an improved method of is profitable) the solvent or liquid used for softenmanufacturing formed or'molded articles from ing or transforming the binder. After drying, exfoliated zonolite (vermiculite) and the like the molded or shaped articles is ready for stor- 1 and a binder, by which the mixing and handling age or use. A few hours to a day, depending of the material is greatly facilitated, the fracon the binder used, is sufficient for the binder to turing of the zonolite during the mixing process "set. The drying maybe hastened by the use minimized, the cost of manufacturing reduced, of an oven or dryer. The mixture may also be and a lighter and less heat conducting article applied and formed in the manner of a plaster, obtained. The heat insulating properties of the that is by the use of a trowel or hawk or similar formed or molded product are enhanced. instrument by which the mass may be compressed An embodiment of apparatus for use in carryand shaped.

ing out the process, is illustrated in the accom- The amount of liquid or solvent which is added panying drawing, wherein: to the exfoliated zonolite is such as to substan- 20 Fig. 1 is a vertical longitudinal sectional view tlally saturate and be absorbed by the exfoliated of said embodiment; and l zonolite. The liquid or solvent may be added to Fig. 2 is a detailed view in side elevation of a the exfoliated zonolite in any suit b and part of a belt used in conjunction with the h pif an excess of the liquid or solvent over that per for feeding material to molds. which the exfoliated zonolite will hold by ab- 5 According to the present invention I take a dissorpt n is s h x e is drained Or other- 2 crete mass of exfoliated zonolite which has the Wise v Prior to the addition f h ry properties of taking up or absorbing a liquid or binder.

liquid solvent, and the particles of which have The dry binder m y be ny on or more Suita diminishable volume, mix it with a binder. in able f h purpose in Vi w an h s lv nt or a dry finely divided state, and thereafter soften q i se i h which is ppr pri to disthe binder, or give it adhesive properties, with solving or otherwise uniting with th dry binder a solvent or liquid to unite the exfoliated zonoused t transform it to an eetil/e di malite particles or the like in the form or shape terial.

of the article desired. The solvent or liquid Examples f suitable binders in y m) which is used to soften the binder mixed with and f a s t or q d ppr priate th for the zonolite is advantageously introduced into ere en mera d as foll w the mixture in an absorbed state, that is the solcement water. vent is absorbed in the zonolite or the like prior lu water acidulated of to the mixing of the zonolite with the dry binder, not with acetic acid. and the mixing thereafter with dry binder is Shellac alcohol.

carried on so as to not expel the absorbed sol- Casein glue water. Y vent. At the end of the mixing operation the Magnesium m nd water containing a1ka batch has substantially the appearance and dis- 11 of sumcient creteness of the original mass of flaky material, centratian to proand is apparently dry. duce a basic salt of a The mixture, with the solvent absorbed in the magnesium.

zonolite, is put into molds, or other apparatus Magnesium sulfate water containing alkafor forming or shaping the same, and the ex- 1 lie of sufiicient confoliated zonolite is compressed to an extent that 3" centration to prosolvent or liquid is squeezed or forced out so as duce a basic salt of to wet and soften the binder so that the exmagnesium,

foliated zonolite particles will be united and stuck Bakelite (soluble form)- acetone and special together, and the discrete mass united in the mixtures.

form or shape of article desired. The mass is -Glyptol resin---" acetone and special held under compression for such a time as necesmixtures.

106. COMPOSITIONS,

COATING R PLASTIC In the drawing there is illustrated an apparatus in which the process may be carried out for forming heat insulating pipe coverings.

Referring to said drawing, numeral 10 designates a mixer of a type to mix discrete material without substantial compression. As here shown, the mixer l0 comprises a vessel ll having a central rotatable shaft l2 therein provided with blades I3. The shaft 12 'is arranged to be rotated very slowly in a direction to turnthe blades to exert a lifting actionon the material within the vessel, so as to cause a circulation which is upward at the center and downward at the sides. The discrete material, zonolite and the like, is placed in the mixer Ill. As heretofore described the solvent or liquid for softening the binder is contained in the zonolite or the like, in the absorbed state. To this zend jthe liquid or solvent may be introduced into the mixer through a spout I for example, beforethe binder is added to the mixture. The zonolite or the like could, however, be introduced into the mixer ID with the liquid or solvent already absorbed therein.

Suflicientliquid or solvent could be added to the zonolite to immerse the same, and the excess of that which the zonolite is capable .of holding by absorption removed by draining, or in other suitable manner. The same thing could be accomplished, by running into the mixer l0 such an amount of the solvent or liquid which will be absorbed by the zonolite.

When the liquid or solvent has been added in the manner described, the zonolite remains in a discrete form with the liquid or solvent which has been added thereto within the inner interstices of the zonolite.

Binding material, in the dry state, and preferably finely divided, is then added to the material in the mixer 10, and thorough mixingeffected in such manner as not to compress the material and thereby expel the liquid or solvent contained therein. The mixture retains the properties of a dry mass.

After the mixing in the mixer I0 is completed, the mixture is advantageously dumped into :a hopper IS. The hopper l8 may be located near a table 20 for supporting a mold. 22 in;.a position to receive batches of the mixture from the hopper l8. After the mold 22 is filled, it may be transferred to a means for compressing the material therein, here shown in the .form-of a cam actuated tamper 25. The tamper acts to compress the exfoliated zonolite, or similar material, and expel from the intersticestherein some 'of the liquid or solvent contained orabsorbed therein. The expelled liquid or solvent wets the binderand causes it to acquire active properties as a binder, so that 'itwill unite and bind the particles of 'the zonolite or like material. Binders such as cement are hydrated and made soft or plastic, and set by crystallization. 'Binders such asglue and the "likedissolve, soften, and harden when dry. The compression is maintained long enough to enable the binder to soften or hydrate. Compression maintained for a few moments, in the case of cementand water, will be suilicient. In the case of shellac and alcohol, compressionmaintained up to minutes may be required.

After the binder is softened, or become plastic, so as to adhere to the zonolite .or ,the like, .the pressure may be relieved from the molded article. .The mold and the molded material .therein may be removed {or air drying, or transferred E5938 HtHzlltNUt.

to a dryer. The dryer, where the liquid or sol-- vent is worth recovering, may be of a type for recovering the solvent.

After the material has been acted on by the tamper 25, and before removal to a dryer or the like, it may be transferred to a means for shaping the face of the material in the mold, which shaping means may be a cam actuated shaper 21. The compression and shaping may howeven'be done together, in which case the gwo functions may be performed by the device For transferring the mold 22 from the filling position-tothe tamper 25 (or to the tamper 25 and'shaper 21) a conveyor, as an intermittently operated belt conveyor 30, may be provided.

The hopper 18 at its lower end is provided with means.35, for feeding batches of the material to successive molds 22. The feeding means 35 is advantageously in the form of a belt 31 having fins .38 plvotally mounted thereon as indicated at 39. Abutments 40 are provided for supporting the fins in one direction against turning. The space between adjacent fins forms a pocket :Iil into which the material in the hopper 18 The-material in the pocket 4| is so light that it does not readily fall out of the pocket at the dumping position, especially if the material in the pockets has been pressed to the extent of squeezing some, of the liquid or solvent out of the particles which come in contact with the fins, and thereby causes adhesion. To, facilitate the dumping of material from the pockets 4| at the dumping position, the fins are provided with arms 44, and a-cam 45 is provided for co-acting with the arms 44 to turn the fins 38 at the dumping position, in a direction to enlarge the pocket and thereby facilitate the falling therefrom of the material in the pocket.

A water or air jet 5D is preferably provided for removing any material or adhesive remaining -on'zthe fins after the material has been dumped from the pockets, and before the fins again enter the hopper.

;The mold 322 in the filling position, is filled with the mixture (carrying the absorbed liquid or solvent) to a heaping amount. The quantity of the material or mixture in the mold has an excess of the order of .10 to percent of the flush capacity of the mold. --1Articles formed or molded from exfoliate vermiculite .or zonolite according to the present processare exceptionally light and porous, and have exceptionally good heat insulating properties.

.The present process .particularly facilitates the handling of exceptionally light weight material, which, at some stage-of the manufacturing process, "must be mixed with an adhesive binder. When exceptionally light weight material such as exfoliated material is mixed with anadhesive binder-it is not easily manipulatable in apparatus, because gravity has but small effect thereon, and masses .of. the material stick to surfaces when many other materials admixed with adhesives would readily fall from such surfaces.

The process effects economies in manufacture, and the finished .product has improved properties by reason of the fact that the interstices within .the mass of the zonolite are less filled with the binder than .when made according to previ ously =,used methods. I

.Theprmess maybe'carricd out by other modes Examine of procedure than that herein specifically described.

What is claimed is:

1. A method of making molded or formed articles (pipe coverings, blocks, boards and the like) from compressible exfoliated zonolite or the like, and a binder, comprising adding to the exfoliated zonolite a liquid in an amount to substantially saturate and be absorbed within the exfoliations of the zonolite said liquid being of a kind which acts with the binder to make it active as abinder, adding a binder in a dry finely divided state to the zonolite containing the absorbed liquid mixing, and, after mixing, expelling liquid from within the exfoliations of the zonolite to soften the binder to unite the zonolite particles in the form or shape of article desired.

2. A method of making molded or formed articles (pipe coverings, blocks, boards and the like), from compressible exfoliated zonolite or the like, and a binder, comprising adding to the exfoliated zonolite a liquid in an amount to substantially saturate and be absorbed within the exfoliations of the zonolite, said liquid being of 'a kind which acts with the binder to make it active as a binder, adding a binder in a dry .flnely divided state to the zonolite containing the absorbed liquid, mixing, and, after mixing, compressing the mixture to expel liquid from within the exfoliation of the zonolite to soften the binder to unite the zonolite particles in the form or shape of article desired.

3. A method of making molded or formed articles (pipe coverings, blocks, boards and the like) from compressible exfoliated zonolite or the like, and a binder, comprising adding to the exfoliated zonolite a liquid in an amount to substantially saturate and be absorbed within the exfoliations of the zonolite, said liquid being of a kind which acts with the binder to make it active as a binder, adding a binder in a dry finely divided state to the zonolite containing the absorbed liquid, mixing, and, after mixing, compressing the mixture to expel liquid from within the exfoliations of the zonolite to soften the binder to unite the zonolite particles in the form or shape of article desired, and maintaining the pressure on the mixture for a few seconds to a few minutes until the binder takes up the requisite amount of the liquid to enable it to act effectively to bind the zonolite particles.

4. A method of making molded or formed articles (pipe coverings, blocks, boards and the like), from compressible exfoliated zonolite or the like, and a binder, comprising adding to the exfoliated zonolite a liquid in an amount to substantially saturate and be absorbed within the capillaries of the zonolite, said liquid being of a kind which acts with the binder to make it active as a binder, adding a binder in a dry finely divided state to the zonolite containing the absorbed liquid, mixing, and, after mixing, compressing the mixture to expel liquid from within the exfoliations of the zonolite to soften the binder to unite the exfoliated zonolite particles in the form or shape of article desired, and maintaining the pressure on the mixture for a few seconds to a few minutes until the binder takes up the requisite amount of the liquid to enable it to act efiectively to bind the zonolite particles, and drying to remove liquid.

JOSEPH A. BABOR. 

